Pressure Equipment Workshop September 2007 – Day 1 In-service inspection Ed Haynes, Guy Baylac Taiex PED & SPVD Israel, September 2007

Layout Introduction Laison with the PED: extension of application, operating instructions Presentation of two typical European legislations Research, Pre-standardization and Data collection Conclusion Taiex PED & SPVD Israel, September 2007

In-service inspection (ISI) – Introduction (1) In-service inspection starts when the equipment is in service. At present in-service inspection surveillance is within the competence of Member States, see PED Article 2, Surveillance of the market, point 2 The provisions of this Directive shall not affect Member States’ entitlement to lay down …, such requirements … to ensure that persons …are protected …during use of the pressure equipment or assemblies …provided this does not mean modifications …in a way not specified in this Directive. Taiex PED & SPVD Israel, September 2007

In-service inspection (ISI) – Introduction (2) The user of the equipment is responsible for in-service inspection, maintenance and repair. If there is a large consensus on the principles there are substantial differences in the planning of inspections and the selection of methods, which may introduce large discrepancies in operating costs. Hence the need of comparison studies, harmonisation, research and standardization. Taiex PED & SPVD Israel, September 2007

extension of application and operating instructions Liaison with the PED: extension of application and operating instructions Taiex PED & SPVD Israel, September 2007

Extension of the domain of application of the PED PED does not apply to the assemblies mounted on the site and after putting in service. But, national legislations may decide that the provisions of Annex I are applicable to: the assemblies mounted on the site and the repairs or modifications of pressure equipment Taiex PED & SPVD Israel, September 2007

Operating instructions and technical documentation (1) The user must define the operating conditions of the equipment using the operating instructions and technical documentation The following elements present a special interest for in-service inspection Mounting including possibilities of inspection Putting in service Use Maintenance including checks by the user Taiex PED & SPVD Israel, September 2007

Operating instructions and technical documentation (2) But also Hazard analysis with reference to hazards arising from misuse Particular features of the Design Reduced safety factors Fatigue analysis (See details later) Creep analysis with monitoring or without monitoring, inspection before creep damage index D reaches 0,5 Data concerning materials and fabrication Materials data e.g. for repairs Standard hydrotest or hydrotest at a higher test pressure Taiex PED & SPVD Israel, September 2007

Operating instructions for a vessel with fatigue operation (1)* Tests during operation Record in a suitable fashion the number of cycles occurring; A plan should be prepared for the inspection of the vessel throughout its life; The vessel should be internally inspected by VT, RT, UT, PT as relevant, at a period not later than 20 % of the allowable life (or the time when the fatigue damage index D reaches 0,2). Early detection of incipient damage is essential: fatigue crack growth generally occurs exponentially; * as given in Annex M of EN 13445-3 Taiex PED & SPVD Israel, September 2007

Operating instructions for a vessel with fatigue operation (2) Supplement internal inspections by non-destructive tests on highly loaded locations especially by surface crack tests and UT; For monitoring inaccessible areas a UT from the outside surface may be appropriate; If the operating conditions deviate from those assumed during design or if damage in the wall is to be expected before the end of the next inspection interval owing to other operating influences, the inspection intervals should be shortened. Conversely, if no incipient cracks are detected during regular inspections, the vessel may be operated further up to the next inspection in the interval laid down or agreed, even if the allowed lifetime as calculated has been reached or has been exceeded. Taiex PED & SPVD Israel, September 2007

Operating instructions for a vessel with fatigue operation (3) Measures to be taken when D = 1 Non-destructive tests should be performed as completely as possible concentrating on the highly stressed locations; If no cracks are detected in the non-destructive tests conducted in the inspection intervals and in the test above, continued operation may be allowed; If cracks or crack-like defects or more extensive damage are found, the component should be replaced, unless continued operation appears admissible by virtue of appropriate measures. Removal of cracks by grinding Grinding the welds to remove all notches Elimination of deformation restraints Change in mode of operation Repair by welding Taiex PED & SPVD Israel, September 2007

Use of design data for in-service inspection The user must prepare an inspection plan As shown by the example, the hazard analysis contained in the operating instructions gives useful information to select the inspection intervals and the critical locations However the hazard does not take into account the consequence of the failure (damage to persons and environment, financial losses) This is the reason why there is a consensus among users to utilize another parameter called criticity or risk and defined as follows: ( criticity = probability of failure x consequence of failure ) Taiex PED & SPVD Israel, September 2007

Taiex PED & SPVD Israel, September 2007

Modern approach to in-service inspection The inspection plan is established in function of the criticity or risk : it is a risk-based analysis The probability of failure is determined using a Fitness For Service analysis including Fatigue Creep Corrosion Fracture mechanics Actual transients Actual material properties Taiex PED & SPVD Israel, September 2007

Presentation of two typical European legislations UK and France UK goal setting legislation FR goal setting and prescriptive legislation Taiex PED & SPVD Israel, September 2007

(UK) Pressure Systems Safety Regulations 2000 Responsibilities for: Designers Manufacturers Installers Owners and Users Repairers Competent Persons Taiex PED & SPVD Israel, September 2007

(UK) Pressure Systems Safety Regulations 2000 Applicable to: Rigid Pressure Vessels, Pipework, Protective Devices Pipework and Protective Devices with Gas Cylinders Pipelines and Protective Devices There are some (partial) exemptions Taiex PED & SPVD Israel, September 2007

(UK) Pressure Systems Safety Regulations 2000 Relevant Fluid Steam Gas > 0,5 bar Liquid with vapour pressure > 0,5 bar Taiex PED & SPVD Israel, September 2007

(UK) In-Service Inspection Requirements Regulation 8 – Written Scheme of Examination Regulation 9 – Examination in Accordance with the Written Scheme Regulation 10 – Action in case of Imminent Danger Taiex PED & SPVD Israel, September 2007

(UK) Regulation 8 – Written Scheme of Examination Owner/User must have a written scheme Pressure vessels Protective devices Pipework Certified by Competent Person Reviewed periodically Taiex PED & SPVD Israel, September 2007

(UK) Content of Written Scheme Parts to be Examined Nature of Examinations Preparations Required Intervals between Examinations Competent Person Date of Certification Taiex PED & SPVD Israel, September 2007

(UK) Examination Frequency Records for System/Similar Plant Current Condition Operating Conditions/Contents Levels of Maintenance Industry Guidance Risk Based Inspection Taiex PED & SPVD Israel, September 2007

(FR) The French legislation on in-service inspection The legislation is contained in: Articles 17, 18 and 19 of the Decree of 13 December 1999 transposing the PED The Ministerial Order of 15 March 2000, text of application of the articles of the Decree. Taiex PED & SPVD Israel, September 2007

The User is responsible for maintenance, surveillance and repairs (FR) General requirements of the Decree dated 13 December 1999 (Article 17) The User must keep the documentation available to the Inspection Authority The User is responsible for maintenance, surveillance and repairs Other requirements address Installation and putting in service Conditions of use Repairs and modifications Taiex PED & SPVD Israel, September 2007

(FR) General requirements of the Decree dated 13 December 1999 (Article 18) Pressure equipment may be subject to the following inspection operations of the Administration Declaration of putting in service Inspection at the time of putting in service Inspection at periodic requalification Inspection after repair or modification Taiex PED & SPVD Israel, September 2007

(FR) General requirements of the Decree dated 13 December 1999 (Article 19) When an industrial establishment operates, under its responsibility and under the management of its inspection service, planified and systematic inspection actions ensuring the safety of pressure equipment the French Administration of the location of the establishment may recognize this inspection service authorize the performance of all or part of the inspections according to article 18 authorize the adjustment of the periodicity of the periodic requalification (Adjusted Regime) Taiex PED & SPVD Israel, September 2007

(FR) In-service inspection rules Described in the Ministerial Order dated 15 March 2000 Modified by the Ministerial Orders of 13 October 2000 and 30 March 2005. The regime of follow-up is based on two components: Periodic Inspections Periodic requalifications by hydrostatic test (except derogation of the Central Commission of Pressure Equipment) Two cases are provided: General Regime (fixed maximum time intervals between two inspections) Adjusted (flexible) Regime (for the sites having an Inspection Service Recognised by the French Administration according to provisions of the Circular DM-T/P 32 510) Taiex PED & SPVD Israel, September 2007

(FR) General regulatory Regime (fixed maximum time intervals between two inspections ) Pressure vessels: Periodic Inspection 40 months maxi Periodic Requalification 10 years maxi Steam generators: Periodic Inspection 18 months maxi Piping: Periodic Inspection inspection programme established by the User. No imposed periodicity Periodic Requalification 10 years. Only certaines lines are concerned in function of PS et DN values (PS> 4 bar & DN > 100) Taiex PED & SPVD Israel, September 2007

(FR) Adjusted Regime of the Chemical and Petrochemical industries* Principle: Inspection planning is based on the criticity (also called risk). ( criticity = probability of failure x consequence of failure ) Inspection Plans are established according to a methodology in conformity with a professional guide approved by the Administration. 2 guides exist for different periodicities of inspection : Periods of 5 & 10 years. Guide DT 32 of U.I.C. and U.F.I.P. Periods > 5 & 10 ans. Guide DT 84 of U.I.C. and U.F.I.P. (presently limited to 6 & 12 years), applicable after a successful period of 5 years spent at the 5/10 years regime. * Also applicable to the Energy Sector Taiex PED & SPVD Israel, September 2007

(FR) Adjusted Regime Pressure vessels: Periodic Inspection inspection plan established by the User. Intervals up to 5 years ( 6 ) maxi Periodic Requalification 10 years (12 ) maxi Steam Generators : Same as for Pressure vessels Piping: Periodic Inspection inspection programme established by the User. Intervals up to 10 years ( 12 ) maxi Periodic Requalification 10 years (12). Only certain lines are concerned in function of the values of PS et DN (PS> 4 bar & DN > 100) Taiex PED & SPVD Israel, September 2007

(FR) Professional Guide DT 84: Contents Purpose of the guide Domain of application Dispositions necessary to apply the methods Method of elaboration of an inspection plan Management of experience feedback Revision of inspection plans Documentation Annexes Degradation modes Adequacy of NDT methods to damages Experience feedback Special provisions applicable to certain families of equipments Limit critical operating conditions Removal of insulation for inspections or periodic requalifications Taiex PED & SPVD Israel, September 2007

(FR) Circular DM – T/P 32 510 The recognition of an Inspection Service depends on the condition of meeting certain requirements: requirements based on the principles of the standard NF EN 45 004:1995 “General criteria for the operation of various types of bodies performing inspection“. complementary requirements specific to Technical Inspection. Taiex PED & SPVD Israel, September 2007

(FR) Requirements of Circular DM – T/P 32 510 Normative and regulatory references Administratives requirements Independence, impartiality and integrity Confidentiality Organisation and Management Quality System Personnel Installations and equipments Methods and inspection procedures Manipulation of samples and objects presented to Inspection Records Inspection reports and inspection certificates Sub-contracting Claims and appeal Co-operation. Taiex PED & SPVD Israel, September 2007

Comparison between the two legislations - summary Good agreement on principles Goal-setting legislation in UK Flexibility of In-Service Inspection Practical nature of Written Schemes Reduced costs by increasing inspection intervals Reduced downtime using alternative inspection techniques Goal-setting and prescriptive legislation in FR Goal-setting legislation for general requirements Flexibility of inspection in large sectors (petro-chemical industries and energy sector) Additional costs due the systematic use of the hydrotest for requalification. (See EPERC TG 3 paper on the EPERC TP Website). No comparison of the safety records of the two systems available Taiex PED & SPVD Israel, September 2007

Comparison Study – issues Is this affecting free-movement or the internal market? What are the differences amongst Member States? Should the arrangements be harmonised? Fixed term or risk-based inspection? What are the objectives and beneficiaries - Trade, Economic, Safety, Citizens? An overview report is being prepared for the Commission Taiex PED & SPVD Israel, September 2007

Research and Standardization Taiex PED & SPVD Israel, September 2007

Harmonisation of legislations in a global market A goal-setting legislation for in service inspection in the spirit of the Pressure Equipment Directive is requested by EPERC To reduce cost discrepancies resulting from different national regulations To foster the development of Risk-Based Inspection (RBI) To increase the safety by concentration of available means on critical locations (higher criticity) The legislation could be supported by the standards resulting from the following R&D actions supported by DG Research RIMAP FITNET Standardization could begin on principles, terminology, ... Taiex PED & SPVD Israel, September 2007

RIMAP This is a 3-level process with RIMAP Principles and procedure at the top level, Tools at the second level and Application workbooks at the third level – inspection planning and optimisation, benchmarking, and sectors including power, petrochemical, steel etc Taiex PED & SPVD Israel, September 2007

CEN WA 24 CEN Workshop Agreement on Risk-based inspection and maintenance procedures will cover the basic RIMAP procedure and its application with examples. Due for publication November 2007 The research work on the model of degradation should continue Taiex PED & SPVD Israel, September 2007

FITNET FITNET is a network on Fitness For Service addressing Fatigue Creep Fracture Mechanics Corrosion FITNET has published 3 volumes (2006) Volume I: FITNET FFS Procedure Volume 2: CASES STUDIES AND TUTORIALS Volume 3: ANNEX A CEN Workshop Agreement is in preparation Taiex PED & SPVD Israel, September 2007

Replacement of requalification by hydrotest by other tests EPERC Report ˝Considerations on the hydrotest,˝  available on the Website, distinguishes Cases where the hydrotest appears justified Cases where it is not useful or even detrimental In the second case, the Report suggests the use of RBI with Fitness for Service methods for planning inspections with appropriate NDT, as this is already done in some countries EPERC also wishes the publication of the CEN Worshop Agreement FITNET in 2007 Taiex PED & SPVD Israel, September 2007

Experience feedback The importance of experience feedback for RIB is well known in the development of calculation models French Union of Chemical Industries and Union of Petrochemical Industries have established data banks of experience feedback Similar data banks exist in other countries It is suggested to evolve towards a European data bank Taiex PED & SPVD Israel, September 2007

Conclusion A lot of actions have been performed in Europe in the domain of in-service inspection with the support of the European Commission, Member States and Industry There is a large agreement on the principles, but noticeable differences among Member States in inspection planning and selection of methods, inducing large differences in operation costs but not significant difference in safety In the global market of today economic issues are essential A European goal-setting legislation supported by European Standards would reduce cost distortions between countries due to in-service inspection and would foster sustainable safety and European competitiveness. Taiex PED & SPVD Israel, September 2007